Method of and arrangement for manufacturing enclosed blocks

ABSTRACT

Blocks with a casing composed of upper and lower parts are produced by inserting the upper and lower parts in an inserting device above and below pushing elements between upper and lower pressing dies of a press, displacing by the pushing elements the lower part in a chamber of a mold towards the lower pressing die and the upper part towards the upper pressing die with self-releasable holding on the latter, withdrawing the inserting device from a pressing region between the upper and lower pressing dies, and cyclically repeating these steps in synchronism with a working stroke of the press.

This is a continuation of application Ser. No. 573,031, filed, Jan. 23,1984, now abandoned, which is a division of application Ser. No.405,874, filed Aug. 6, 1982, now U.S. Pat. No. 4,449,905.

BACKGROUND OF THE INVENTION

The present invention relates to a method of and an arrangement formanufacturing enclosed blocks. More particularly, it relates to a methodof and an arrangement for manufacturing blocks having a casing assembledfrom upper and lower parts, wherein the lower part is inserted into amold chamber, the mold is filled with a filling material to be pressed,the upper part is applied, and the block is subjected to pressurebetween upper and lower pressing dies that engage the upper and lowerparts of the block casing.

The thus manufactured refractory blocks, in which the filling materialis predominantly a ceramic mass, are used for lining converters in whichsteel is melted from crude iron, such as Bessemer or Thomas converters.It has been recognized in the Steel industry that the casing of theindividual blocks significantly increases the service life of theconverter lining composed of these blocks. In accordance with a knownmethod of manufacturing, a blockmaking press is utilized, for example asdescribed in the German Offenlegungsschrift No. 2,741,800; it hasvertical upper and lower pressing dies arranged opposite one another,and a mold table that is axially movable relative to the pressing dieand supports a mold with a mold chamber through which the pressing diescan move. During a working stroke of the press, in which the moldchamber is closed from below by an upper surface of the lower pressingdie, the lower part of the block casing is inserted by hand into themold chamber, then a filling slider which is downwardly open andcontains the filling material displaces during a further working stroketo a region above an upper surface of the mold so that the fillingmaterial falls into the mold chamber, and finally the upper part of theblock casing is placed by hand onto the filling material and compressedby simultaneous raising of the mold table and the lower pressing die. Inconnection with this, either the filling material is first somewhatcompressed in the mold before application of the upper part of the blockcasing and only after this the upper part is applied by hand, or thelower surface of the upper pressing die is provided with a holdingtemplate in which the upper part can be inserted in a position suitablefor its treatment. The thus pressed block is then released by upwardlydisplacing the lower pressing die so that its pressing surface is flushwith the upper surface of the mold, and then removed from the pressingsurface by hand.

The above described method utilizes manual labor and therefore istime-consuming and expensive. Moreover, the insertion of the parts ofthe block casing by a worker requires his high concentration to preventaccidents. The known method is not suitable for manufacturing the blocksin great volumes required by wear-reducing properties of these blocks.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide amethod of and an arrangement for manufacturing enclosed blocks, whichavoid the disadvantages of the prior art.

More particularly, it is an object of the present invention to provide amethod of and an arrangement for manufacturing enclosed blocks, inaccordance with which the blocks can be produced automatically withoutmanual labor.

In keeping with these objects and with others which will become apparenthereinafter, one feature of the present invention resides, brieflystated, in a method having an operation which is cyclically repeated insynchronism with a working stroke of a press and includes automaticallyinserting upper and lower parts of a block casing above and belowpushing means into inserting means between upper and lower pressing diesof the press, displacing by the pushing means the lower part of theblock casing in a chamber of a mold towards the lower pressing die andthe upper part of the block casing towards the upper pressing die, forautomatically releasable holding on the latter, and withdrawing theinserting means from a pressing region between the upper and lowerpressing dies before a pressing step.

When the method is carried out in accordance with the present invention,the inserting means provided with the pushing means automatically bringthe upper and lower parts of the block casing in a position required forthe pressing step, so that manual action is eliminated and a faster andundisturbed working stroke of the press is guaranteed. In addition toreduction of manufacturing expenses achieved, a worker for the press isno longer needed and therefore accident danger is excluded.

In accordance with another advantageous feature of the inventive method,the lower and upper parts of the block casing are supplied into theinserting means from a magazine. Thereby after charging the insertingmeans, the upper and lower parts of the block casing are alwaysavailable synchronously with the working stroke, so that a fasterworking stroke can be performed in a simple manner.

Still another advantageous feature of the inventive method is that theupper and lower parts of the block housing are supplied into theinserting means from opposite sides of the latter. Thereby the upperpart and the lower part are introduced into the inserting means inspatially separated regions so as not to disturb the respective oppositeworking steps.

A further advantageous feature of the present invention which providesfor a simple operational and process course is that the lower and upperparts of the block casing are introduced into the pressing region whenthe inserting means is withdrawn from the latter, and thereafter theinserting means is inserted into the pressing region.

Finally, still a further advantageous feature of the inventive method isthat prior to the introduction of the inserting means into the pressingregion, the lower pressing die is displaced in the mold chamber so thatan upper surface of the lower pressing die is flush with an uppersurface of the mold, and retracting of the lower and upper part of theblock casing is performed immediately after moving back of the lowerpressing die from the upper surface or raising of the mold table, afterthe insertion of the inserting means into the pressing region.

Another feature of the present invention is an arrangement formanufacturing blocks in a press having upper and lower pressing dies, anaxially movable mold table, and a mold with a mold chamber through whichthe pressing die moves, wherein the arrangement has inserting meansmovable into a pressing region between upper and lower pressing dies ina direction transverse to the axis of the pressing dies and arranged sothat upper and lower parts of the block casing can be inserted into theinserting means, pushing means provided in the inserting means andarranged to displace the upper and lower casing parts toward the upperand lower pressing dies, and holding means arranged to hold the upperpart of the block casing on the pressing die and automatically torelease the same during pressing.

Such an arrangement in which blocks having the casings are manufacturedfully automatically possess the advantage that it can be easily utilizedin a conventional block making press.

Another advantageous feature of the inventive arrangement in the senseof its design is that the pushing means includes pressure mediumoperated cylinder-and-piston units with upper and lower pistons engagingwith and displacing the upper and lower parts of the block casing.

Since the casing of blocks which are utilized for converters is composedof sheet metal, it is advantageous when the holding means on the upperpressing die is advantageously formed as a magnetic plate.Alternatively, it is also possible to form the holding means on theupper pressing die as a mechanical holder. It works as a holdingtemplate from which the upper part pressed during the pressing step ofthe block is released.

A further structural feature of the inventive arrangement is that theinserting means is provided on at least one of its sides parallel to thedisplacing direction, with at least one charging opening for upper andlower parts of the block casing supplied from a magazine. It isadvantageous when the charging openings are provided at both end sidesfor the upper and lower parts of the casing, respectively. In this casethe upper and lower parts can be displaced in a simple manner during theoperation into the inserting means.

Since the pushing means is operative at both sides, or in other wordsacts toward the upper and lower pressing dies, it is advantageous whenthe pushing means is arranged between the upper and lower parts of theblock casing in the inserting means.

Finally, when the inventive arrangement is utilized in the press andthere are a filling slider movable along an upper surface of the moldtransverse to the pressing die and a block gripper coupled with thefilling slider, the inserting means is arranged so that it is insertablebetween the filling slider and the block gripper. In this constructionthe operational course of the inserting means is especially advantageousto integrate the working cycle of the press.

The novel features of the present invention are set forth in particularin the appended claims. The invention itself, however, will be bestunderstood from the following description of a preferred embodimentwhich is accompanied by the following drawing.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a fragmentary perspective view of enclosed blocks forming apart of a lining of a converter;

FIG. 2 is a front elevational view of a press in which an arrangement inaccordance with the instant invention is installed, and a method inaccordance with the instant invention is performed, for manufacturingenclosed blocks;

FIG. 3 is a fragmentary sectional view, showing the press at the start;

FIG. 4 is a plan view thereof;

FIG. 5 is a fragmentary sectional view, similar to FIG. 3, but showingan other step of the method; and

FIGS. 6-10 are views similar to FIG. 5, but showing different succeedingsteps.

DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 shows a part of a lining of a converter for making steel fromcrude iron. The lining is composed of a plurality of refractory blocks 1which are arranged in rows in offset relationship, so as to form acompact wall. The converter partially shown in FIG. 1 has a round shapein the plane view, as a rule, so that the blocks are somewhatwedge-shaped in correspondence with this round shape. The conicallydecreased sides of the blocks face toward the melting chamber of theconverter. With the exception of the conically decreased side 2 and theconically increased side 3, other sides of the blocks are closed by acasing which has a U-shaped lower part 4 with side walls 5 and 6, and anupper part 7 connecting the side walls with one another. The casing iscomposed from a sheet metal.

For guaranteeing a connection between the lower part 4 and the upperpart 7 of the pressed block 1, anchoring elements 8 are welded on theupper part 7 and extend toward the lower part 4. The anchoring elements8 are provided with openings 9 or projecting formations. This providesfor a firm connection with a pressing material 10 which fills theinterior of the casing, for example a ceramic pressing material.

A press for manufacturing the block 1 is shown in FIG. 2 and has anupper pressing die 12 supported on a press crossbar 11, and a lowerpressing die carried by a press table 13. The press table 13 is movableby a pressure-medium operated drive along columns 16 which are connectedat their foot end with a bottom plate 15 and at their head end with thecross bar 11 and extend vertically.

A mold table 18 which carries a mold 17 is also movable by apressure-medium operated drive along the columns 16 and arranged betweenthe press table 13 and the crossbar 11. The mold table 18 has a throughgoing opening 19 through which the lower pressing die 14 moves in a moldchamber 20. The mold chamber 20 is formed in the mold 17 and has endsides which are open toward the upper and lower pressing dies 12 and 14.

A filling slider 22 is arranged on a support 21 located laterally on themold table 18 and is displaceable transverse to the pressing dies 12 and14. The filling slider 22 is formed as a material container provided foraccommodating a pressing material 24 and having an upper lower side 23which faces toward the mold 17. A transporting band 25 for withdrawingthe manufactured blocks 1 is arranged at the press side opposite thesupport 21.

Manufacturing of the blocks 1 is performed in accordance with a methodwhich is schematically shown in FIGS. 3-10, wherein FIG. 3 shows thepress in the initial position of its cyclical working process.

In this initial position, the material container or filling slider 22 ischarged with the pressing material 24 and the lower pressing die 14 isinserted into the mold chamber 20 so that a pressing surface 26 of thelower pressing die is flush with an upper surface 27 of the mold 17, thepressing surface 26 and the upper surface 27 facing toward the upperpressing die 12. An inserting device 29 for the casing of the block 1 isbrought between the filling slider 22 and a block gripper 28 connectedtherewith.

In this initial position of the press, in which the pressing cycle isfinished, lies the manufactured block with its casing assembled from theupper and lower parts 7 and 4 open and ready to grip at the height ofthe upper surface 27 of the mold 17. For adjusting this position, themold table 18 with the mold 17 and the support 21, which forms with theupper surface 27 of the mold 17 a flush displacing surface 30 for thefilling slider 22, must be lower by the height of the manufacturedblock 1. This is performed by a downward displacement of the press table13 with the mold table 18 and the support 21. While in the shownembodiment the upper pressing die is immovable, in other systems thelower pressing die 14 is formed stationary or both pressing dies 12 and14 are displaceable.

FIG. 4 shows the initial position of the press in plan view. The lowerpart 4 and the upper part 7 of the block casing are moved in directionsof the arrows 31 and 32 in the inserting device 29 which isadvantageously arranged between the filling slider 22 and the blockgripper 28 connected therewith. The insertion of the lower part 4 andthe upper part 7 is performed from not shown lateral cassette magazineshydraulically, pneumatically or mechanically. The lower part 4 can beinserted into the inserting device from one side of the press, and theupper part 7 can be inserted into the same from the other side of thepress, to satisfy strict requirements to space consumption.

The inserting device 29 further has a pushing device 33 for the lowerpart 4 and the upper part 7. The pushing device 33 is composed ofseveral pressure-medium operated cylinder-and-piston units withcylinders 34 and 35 and pistons 36 and 37 engaging with the lower part 4and the upper part 7, so that the latter can be displaced in directiontoward the neighboring pressing dies 12 and 14.

In FIG. 5 the inserting device 29 loaded with the lower part 4 and theupper part 7 is displaced to its unloading position between the lowerand upper pressing dies 14 and 12 in the thus formed pressing region.The block gripper 28 is somewhat raised relative to the mold 17.

In the next step shown in FIG. 6, the mold table 18 with the mold 17, aswell as the filling slider 22, the inserting device 29 and the blockgripper 28 with the finally pressed block 1 are lifted, so that therequired mold chamber 20 is again formed for a next block 1 to bepressed. Immediately after this, the pushing device 33 is brought tooperation and pushes with the cylinder 34 and the piston 36 the U-shapedlower part 4 from the mold chamber bottom formed by the pressing surface26 of the lower pressing die 14. At the same time the pushing device 33pushes with the cylinder 35 and the piston 37 the upper part 7 againstthe pressing surface 38 of the upper pressing die 12. Alternatively tothis raising of the mold table, the lower pressing die 14 can beretracted relative to the mold 17 for forming the mold chamber 20.

FIG. 7 shows a further step of the manufacturing process of the block 1.The pistons 36 and 37 of the cylinders 34 and 35 are further retracted.The upper part 7 is held on the upper pressing die 12 by a magneticforce or with the aid of other mechanical holders.

Finally, the filling slider 22, the inserting device 29 and the blockgripper 28 are further displaced, as shown in FIG. 8, and the fillingslider is retained approximately centrally to the mold chamber 20.During this movement the ceramic pressing material 24 falls into themold chamber 20 as the inserting device 29 is withdrawn from thepressing region, and the block gripper 28 opens its holding device 39,so that the block produced in the preceding step falls onto the runningconveyor band 25.

For improving the distribution of the ceramic material in the moldchamber 20, the filling slider 22 can reciprocate or also be identicallyretracted to remove excess ceramic pressing material 24 from moldchamber 20. The press is now available for the pressing process as shownin FIG. 9.

The mold table 18 and the press table 13 are further displaced togetherupwardly under the action of the hydraulic drive, so that the upperpressing die 12 with the upper part 7 is introduced into the moldchamber 20 to such extent until it abuts against the free ends of thewalls 5 and 6 of the U-shaped lower part 4 or it attains a predeterminedresistance, the upper pressing die 12 is released and the lower part 4with the upper part 7 form together the casing of the block 1 in itsclosed form, as can be seen in FIG. 10. At this point the manufacturingcycle is repeated.

I wish it to be understood that I do not desire to be limited to theexact details of construction shown and described, for obviousmodifications will occur to a person skilled in the art.

Having thus described the invention, what I claim as new and desire tobe secured by Letters Patent, is as follows:
 1. A method formanufacturing refractory blocks in a pressing region located betweenopposing upper and lower pressing dies, comprisingadvancing said lowerpressing die through a mold chamber with a pressing surface of saidlower pressing die facing said upper pressing die so that said pressingsurface of said lower pressing die becomes flush with an upper surfaceof a mold facing said upper pressing die, automatically inserting upperand lower block casings on a feeding means which includes pushing means,said feeding means being movable along a horizontal plane which passesthrough said pressing region from a first side thereof to a second sidethereof, while inserting said upper and lower casings on said feedingmeans, bringing a previously formed refractory block in said pressingregion into position for removal, bringing said feeding means with saidupper and lower block casings into said pressing region between saidupper and lower pressing dies, while simultaneously removing saidpreviously formed refractory block from said pressing region,withdrawing said lower pressing die from said upper surface of saidmold, by means of said pushing means, ejecting said lower block casinginto said mold chamber within said pressing region while simultaneouslyejecting said upper block casing toward said upper pressing block forself-releasable holding thereon, withdrawing said feeding means fromsaid pressing region while simultaneously bringing filling means intosaid pressing region to fill said lower block casing with saidrefractory material, removing excess refractory material from saidpressing region by withdrawing said filling means therefrom, pressingsaid upper and lower block casings together by means of said upper andlower pressing dies to form a refractory block, and cyclically repeatingeach of said steps in synchronism with said pressing step of said upperand lower pressing dies.
 2. The method of claim 1 wherein said upper andlower block casings are inserted onto said feeding means on said firstside of said pressing region, and said feeding means are withdrawn fromsaid pressing region to said second side of said pressing region.
 3. Themethod of claim 2 further comprising returning said feeding means tosaid first side of said pressing region.
 4. The method of claim 3wherein said feeding means are returned to said first side of saidpressing region prior to said pressing step.
 5. The method of claim 4wherein said automatic inserting step includes automatically feedingsaid upper and lower block casings above and below said pushing meansfrom a magazine.
 6. A method for manufacturing refractory blocks in apressing region located between opposing upper and lower pressing dies,comprisingadvancing said lower pressing die through a mold chamber witha pressing surface of said lower pressing die facing said upper pressingdie so that said pressing surface of said lower pressing die becomesflush with an upper surface of a mold facing said upper pressing die,automatically inserting upper and lower block casings on a feeding meanswhich includes pushing means, said feeding means being movable along ahorizontal plane which passes through said pressing region from a firstside thereof to a second side thereof, said upper and lower blockcasings being inserted onto said feeding means on said first side ofsaid pressing region, said upper and lower block casings beingautomatically fed above and below said pushing means from a magazine,while inserting said upper and lower casings on said feeding means,bringing a previously formed refractory block in said pressing regioninto position for removal, bringing said feeding means with said upperand lower block casings into said pressing region between said upper andlower pressing dies, while simultaneously removing said previouslyformed refractory block from said pressing region, withdrawing saidlower pressing die from said upper surface of said mold, immediatelyafter withdrawal of said pressing die from said upper surface of saidmold, by means of said pushing means, ejecting said lower block casinginto said mold chamber within said pressing region while simultaneouslyejecting said upper block casing toward said upper pressing block forself-releasable holding thereon, withdrawing said feeding means fromsaid pressing region to said second side of said pressing region whilesimultaneously bringing filling means into said pressing region to fillsaid lower block casing with said refractory material, removing excessrefractory material from said pressing region by withdrawing saidfilling means therefrom, returning said feeding means to said first sideof pressing region, pressing said upper and lower block casings togetherby means of said upper and lower pressing dies to form a refractoryblock, and cyclically repeating each of said steps in sychronism withsaid pressing step of said upper and lower pressing dies.